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Ever increasing performance requirements of components demand higher performance from materials. Materials such as Ni, Co or Ti alloys are well known for their high temperature properties and excellent wear/corrosion resistance. Building a whole part with such expensive alloys may be cost prohibitive. Traditional coating technologies have metallurgical limitations when costing these alloys onto low cost substrates. The following summarizes some of the challenges:

Cost of materials

Metallurgical bonding

Coating thickness

DMST SOLUTION

With its closed loop feedback system and five-axis deposition capability, the DMST process can coat expensive metals onto low cost substrates of different geometries. Further, it creates a metallurgical bond and can be applied up to millimeters thick. Coating parts with expensive but high performance materials offers a cost effective solution to the material challenges. This allows great savings on material costs while still providing performance functionality of the parts.

CAPABILITIES

Apply wear and/or corrosion resistant coatings

Coating thickness can range from microns to millimeters

Metallurgically bonded DMST coatings do not spall or peel off like mechanically bonded coatings

Demands for longer life and higher efficiency results in higher wear and tear of components requiring better methods for repairing and re-manufacturing. The need for high performance components for sustainable operations, coupled with the ever increasing cost of materials, has intensified the search for re-manufacturing technologies that offer better quality and a near net shape finish. Some of the challenges for successful re-manufacturing are:

Part distortion

Large Heat Affected Zone (HAZ)

Integrity of repair

DM3R SOLUTION

Direct Metal Deposition (DMD) is an advanced additive manufacturing technology that offers an excellent solution to the challenges above. DM3R uses the DMD process to repair and rebuild worn/damaged components that are hard to weld. This additive metal technology can also reconfigure parts to accommodate design changes which saves and reduces lead time.

Additive Manufacturing (AM) is a group of emerging technologies that create objects from the bottom up by adding material one cross section layer at a time. AM is great for design freedom and building complex geometries; however, as a means for fabricating end-use components, it was limited by the following:

Material selection such as plastics or polymers

Part density

Only small parts available

DM3D SOLUTION

DM3D is a 3D Printing (aka Free Form Fabrication) application which is not new to our organization. Direct Metal Deposition (DMD) has long been the leader in additive metal technology. DMD is a laser-based, additive fabrication technology which can create fully dense larger parts from various metals and alloys.

Higher performing materials are necessary to meet the demand of technological advances. The difficulty has been to combine two or more materials with distinct properties into a single component for enhanced product performance. One such difficulty is the fabrication of components that combine a high conductivity core (heat transfer) with a high durability surface (strength or hardness) for a variety of manufacturing applications. The challenges of developing such multi-material components are:

Joining dissimilar metals/alloys

Part distortion during fabrication

SOLUTION

DMD can add a variety of materials precisely at select locations on the part which allows for fabricating multi-material components with functional properties. This innovative solution eliminates the need for assembling multiple parts with different metals which saves cost and reduces manufacturing time.